Have you ever imagined that upgrading a small water pump could significantly boost your car's performance? Intercooler water spray systems, as a cost-effective cooling solution, are gaining popularity among DIY enthusiasts. The core component—the water pump—directly impacts the system's spray efficiency and overall performance. In our previous article, we tested a batch of second-hand OEM water pumps as the foundation for a custom intercooler spray system. Now, we continue testing the remaining pumps, compile all data, and finally reveal the champion of this evaluation!
Windshield Washer Pump Test Results (Continued)...
1970 Mercedes-Benz 250
As the first European model pump in our test, this classic Mercedes pump delivered impressive results. At 14.2V test voltage, when connected to a Spraying Systems nozzle, it achieved a remarkable maximum output pressure of 34psi, easily surpassing many newer models. Even more impressive, at 34psi pressure, the flow rate reached 225ml/minute. The startup peak current was 5.5 amps, settling to 3.1 amps during continuous operation.
Manufactured by Hella, this compact pump stands about 70mm tall with a 30mm diameter. Both inlet and outlet ports measure 6.5mm in diameter, with the inlet located at the pump's end.
This robust, high-performance pump outperforms many modern alternatives, making it an excellent choice for budget-conscious DIYers.
1983 Volvo 760
This larger Volvo pump appeared promising, but did it deliver? While functional, it wasn't the best performer. At 14.2V with a Spraying Systems nozzle, the pump produced audible strain during operation, with pressure fluctuating between 30-34psi. At maximum pressure, flow reached 205ml/minute.
Notably, this VDO-manufactured pump required warm-up time to reach full pressure, explaining its relatively low startup current of 3.4 amps. Featuring sturdy mounting brackets and dual 6mm outlets, its 26mm diameter and 84mm height make it suitable for remote installations.
If you need a pump separate from your reservoir, this Volvo unit works—just be selective to find a stable performer.
1982 Holden Jackaroo
Contrary to expectations for 4WD vehicles, this Jackaroo pump disappointed. With only 27psi maximum pressure and 175ml/minute flow at full pressure, it performed worse than standard Mazda or Hyundai pumps. Startup current peaked at 4.2 amps before dropping to 1.9 amps.
Despite its rugged metal housing (66mm tall, 30mm diameter), we cannot recommend this underperforming pump with its 10mm inlet and 5mm outlet.
1971 Rambler Rebel
This Rebel pump mirrored the Jackaroo's disappointing performance with 26psi maximum pressure and 170ml/minute flow. Current draw measured 3.8 amps at startup, stabilizing at 2.1 amps.
Its main distinction was a larger 17mm inlet (versus 5mm outlet) and unique reservoir mounting via threaded connection. At 58mm tall and 29mm diameter, this pump shares specifications with some 1970s Chrysler models—but that's no reason to seek it out.
Nissan Terrano (Headlight Washer Pump)
This heavyweight contender—originally from a Japanese-market Nissan Terrano 4WD (sold as Pathfinder elsewhere)—delivered staggering performance. Measuring 140mm tall and 57mm diameter (with 8mm inlet, 5.5mm outlet), it dwarfed other pumps.
At 14.2V with test nozzle, it produced 55psi output pressure—enough to create an ultra-fine mist! Flow reached 290ml/minute at full pressure, demanding a large reservoir. The trade-off? Significant noise/vibration (mitigated by factory rubber isolators) and high power draw: 12.5 amps startup, 6.7 amps continuous.
This powerhouse requires heavy-duty wiring but delivers professional-grade performance.
The Verdict
Our testing revealed distinct winners. Most windshield washer pumps produced 20-30psi, with only the Ford EA pump failing to reach 20psi. Four pumps exceeded 30psi: Volvo, Mercedes, Holden VT Commodore, and the Terrano. The Holden VT Commodore led this group at 38psi—137% better than the worst performer.
But the Terrano stood alone—its 55psi maximum pressure dwarfed the Ford EA by 244%!
The relationship between pressure and flow proved consistent—higher pressure enabled greater flow. While weaker pumps couldn't break 200ml/minute, the European and VT Commodore pumps easily surpassed this. The Terrano? A class-leading 290ml/minute.
Final Recommendations
For most applications, the Holden VT Commodore windshield washer pump represents the sweet spot—excellent performance, modern availability, and direct reservoir compatibility. It's the safe choice.
The Mercedes and Volvo pumps remain viable for custom installations, though their age may cause performance variability.
But for uncompromising performance? The Nissan Terrano's headlight washer pump stands unchallenged. Its 55psi output rivals professional intercooler spray systems, making it our undisputed champion.
Pricing Note:
Used washer pumps typically cost little (sometimes free from salvage yards), while headlight washer pumps like the Terrano's command higher prices due to rarity. Either way, performance upgrades needn't break the bank.
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